Professional Documents
Culture Documents
General
1.0
2.0
3.0
F
F
F
F
F
4.0
4.1
4.2
4.3
4.4
F
F
5.0
5.1
Accessories
Press- and bending tools
Closing- and end cap
Wall duct and distributing manhole
Twin-accoutrement and one-time-ball-valve
F
F
F
F
6.0
6.1
6.2
6.3
F
F
F
7.0
7.1
7.2
Assembling
Delivery, unloading and storage
Cutting and processing
Laying and underground work
F
F
F
8.0
8.1
8.2
Design
Maximal pipe laying lengths isoflex / isocu
Application isoflex and isocu
Application isopex
House connection
F
F
F
F
9.0
9.1
9.2
9.3
FLEXIBLE PIPES
General
The flexible pipe system of isoplus is especially suited for
house connections and extension works later on. It can be
easily being led around obstructions such as buildings, trees or
other pipeline systems. It can be also used for complete lowtemperature systems in lower dimensions.
Because of the continuous production of isoplus-flexible pipes
a longitudinal water tight compound system will be reached.
That means the three basic materials (medium pipe + insulation
+ jacket pipe) are connected by axial force with each other. Due
to very small bending radius of flexible pipes, it is possible to
choose always the direct way around obstructions respectively
to the area of the house connection.
Due to the big delivery lengths the pipe laying works can be carried out in a short time, the operational
works can be reduced to a minimum. Also the underground construction works can be reduced
essentially because of the extremely narrow trenches. For these reasons the flexible pipe system of
isoplus represents a technically fully developed and economically as well as ecologically perfect laying
method for district heating systems.
Heat-Insulation
Flexible pipes will be insulated with polyurethane-hard foam (PUR), consisting of component A = Polyol
clear and component B = Isocyanat dark, tested acc. to EN 253. During production continuously foamed
around the medium pipe, a high quality heat insulation with an excellent thermal conductivity, PUR =
maximal 0,024 W/(mK), at low specific weight will be reached, due to an exothermal chemical reaction.
isoplus is using generally Cyclopentan driven foam, 100% free of Freon and therefore environment
friendly. That means the very best heat insulation values will be reached at lowest possible ODP- and
GWP- values, ODP (ozone reducing potential) = 0, GWP (green house potential) = < 0,001 !
Jacket-Pipe
The jacket pipe of the flexible pipes consists of proved polyethylene with even surface. Polyethylene Low
Density is a seamless, tough elastic thermo-plastic material which will be continuously extruded on to the
PUR foam during the production procedure. General quality requirements as well as measures and
weights in accordance to DIN 8073 resp. DIN 8072, thermal conductivity PE = 0,35 W/(mK).
PEHD is mentioned in all national and international standards, respectively recommendations, as the only
suitable material, due to the resistance against weather conditions and UV-rays, as well as against
practically all chemical compounds existing in the soil.
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F 1.0
F L E X R O H R
Medium Pipe
The isoflex-medium pipe consists of a seamless, cold drawn
precision steel pipe with especial measure-exactness and plain inner
surface. Measures, specification and static values and tolerances acc.
to DIN 2391-1, material St 35.8 S/I, No. 1.0305. Technical delivery
conditions acc. to DIN 17175 with works certificate (APZ) acc. to EN
10.204-3.1.B.
Connection Technology
The connection of the steel pipe will be made by autogenouslywelding or by Wolfram-Inert gas (WIG) welding procedure.
Operating Conditions
Maximum operating temperature Tmax:
130 C
Maximum operating pressure pB:
25 bar
Maximum permissible axial-tension max:
150 N/mm
Leak detecting:
without; single pipe IPS-Cu as special production
Possible liquids: Heating water as well as other material resistant liquids
Property
Volume weight
Tensile stress Rm
Yield stress Re
Wall roughness k
Unit
kg/dm
N/mm
N/mm
mm
Unit
N/mm
W/(mK)
kJ/(kgK)
K-1
Value
211.000
52,33
0,43
12,5 10-6
Pipe
Dimension Steel Pipe
Outside
Type
isoflex - Standard
isoflex - 1 x reinforced
isoflex - Double
JacketDelivery- Maximum
coilPipe
length in
Wallthickness Outside- 1 m steps outside-
Minimum
bending
radius
Weight
without
water
da
in mm
s
in mm
Da
in mm
L
in m
dR
in mm
r
in m
G
in kg/m
28,0
28,0
2 28,0
2,0
2,0
2,0
75
90
90
24 - 100
24 - 100
24
2220
2300
1980
0,8
0,9
0,9
1,95
2,15
3,17
isoflex - S
isoflex - 1
Double
Watercontent
VolumeFlow
Dimensioning
FlowTransmitted Capacity
Speed
P in kW
v
in l/m
V
in m/h
w
in m/s
0,452
0,452
0,452
0,977
1,303
1,629
0,60
0,80
1,00
at spread
20 K
23
30
38
30 K
34
45
57
40 K
45
61
76
Heat Loss
Coefficient
kER/DR
in
W/(mK)
0,1451
0,1229
0,2636
60 K
8,704
7,376
15,821
50 K
7,253
6,146
13,187
The mentioned data are based on a medium specific heat capacity [cm] of the water 4.187 J/(kgK). Soil
covering height [H] of 0,60 m (Surface jacket pipe to surface of the area), heat conductivity of soil [E] of
1,2 W/(mK), a medium temperature of soil [TE] of 10 C as well as a medium pipe distance of 100 mm at
single pipes.
(59) TM = (TVL + TRL) : 2 TE ; Example: (90 + 70) : 2 10 = 70 K average temperature.
F 2.0
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F L E X R O H R
Medium Pipe
The isocu-pipe consists of a seamless, cold drawn copper pipe acc.
to EN 1057. Dimension, specification and static data and tolerances
acc. to DIN 1754, material Cu-DHP/R 220, No. 2.0090, in standard
wall thickness, technical delivery conditions acc. to DIN 17671. isocudouble with longitudinal mark of one pipe.
Connection Technology
The connection of the copper pipe will be made by capillary-solderingfittings, acc. to DIN 2856 with the same wall thickness than the pipes,
or by special suitable press fittings. It is not allowed to enlarge the
copper pipes. The recommendations and/or instructions of the
manufacturers of the fittings concerning soldering procedure and kind
of soldering have to be considered.
Operating Conditions
Maximum operating temperature Tmax:
110 C with soldering fittings; 130 C with press fittings
Maximum operating pressure pB:
25 bar
Maximum permissible axial-tension max:
110 N/mm
Leak detecting:
without; single pipe IPS-Cu as special production
Possible liquids: All potable and heat-water as well as other material resistant liquids
Property
Volume weight
Tensile stress Rm
Yield stress Re
Wall roughness k
Unit
kg/dm
N/mm
N/mm
mm
Unit
N/mm
W/(mK)
kJ/(kgK)
-1
K
Value
132.000
364,00
0,386
-6
16,8 10
Pipe
Dimension Copper Pipe
Outside
Type
isocu I
isocu II
isocu - Double I
isocu - Double II
JacketDelivery- Maximum
coilPipe
length in
Wallthickness Outside- 1 m steps outside-
Minimum
bending
radius
Weight
without
water
da
in mm
s
in mm
Da
in mm
L
in m
dR
in mm
r
in m
G
in kg/m
22,0
28,0
1,0
1,2
65
75
25 - 360
25 - 360
2500
2530
0,8
0,8
1,14
1,57
2 22,0
2 28,0
1,0
1,2
90
90
25 - 250
25 - 200
2530
2530
0,9
0,9
1,80
2,40
isocu I
isocu II
Double I
Double II
Watercontent
VolumeFlow
Dimensioning
FlowTransmitted Capacity
Speed
P in kW
v
in l/m
V
in m/h
w
in m/s
0,314
0,515
0,679
1,482
0,314
0,515
0,905
1,853
at spread
Heat Loss
Coefficient
kER/DR
in
30 K
24
52
40 K
32
69
W/(mK)
0,60
0,80
20 K
16
34
0,1332
0,1451
70 K
9,323
10,156
60 K
7,991
8,705
50 K
6,659
7,254
0,80
1,00
21
43
32
65
42
86
0,1971
0,2637
13,797
18,457
11,828
15,823
9,859
13,188
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F 3.0
F L E X R O H R
Medium Pipe
The isopex-pipe consists of PE-Xa, basic material PE, general
material requirements acc. to DIN 16892, pipe series respectively
measures acc. to DIN 16893. isopex-double with a bar-code fixed in
longitudinal direction of the pipe, for identification of a pipe.
PolyEthylene is an organic connection of carbon- and hydrogen
molecules. For PolyEthylene-cross-linked (X) H-atoms will be
removed out of the molecule chains, irreversible carbon-connections
will develop, which will form a cross link between the chains. During
extrusion of PE peroxide (a) will be added, the oxygen will bind the
hydrogen atoms. The mechanical high resistant, but not weldable
material PE-Xa comes into being.
Heating pipe: Pipe-range 1; series 5,04; SDR 11,08; operating pressure max. 6 bar, PN 12,5; with red
coloured organic oxygen diffusion barrier of E/VAL (Ethylenvenylalcohol) acc. to DIN 4726. According to
AGFW-information FW 420 District Heating pipelines with plastic-medium pipes (PMR).
Sanitary pipe: Pipe-range 2; series 3,15; SDR 7,30; operating pressure max. 10 bar, PN 20; tested acc.
to DVGW- documentation W 531, with DVGW- and VGW-inspection mark.
Connection Technology
The connection of PE-Xa pipes is made in buried sections preferably with press connections- and
connection pieces, see F 4.4. Inside of buildings as well as for sanitary installations also screwed
connections may be used.
Operating Conditions
Maximum permanent operating temp. TB max: 80 C
Maximum operating temperature Tmax:
95 C
Maximum operating pressure pB:
see page F 4.2 + F 4.3
Leak detecting:
general without
Possible liquids: Potable- and heat-water, chemicals as well as other material resistant liquids
Property
Volume weight
Tensile stress Rm
Yield stress Re
Wall roughness k
Unit
kg/dm
N/mm
N/mm
mm
Unit
N/mm
W/(mK)
kJ/(kgK)
-1
K
Value
600
0,38
2,3
-5
20,0 10
Type
H - 25 / H - 25 v
H - 32 / H - 32 v
H - 40 / H - 40 v
H - 50 / H - 50 v
H - 63 / H - 63 v
H - 75
H - 90
H - 110
F 4.0
thickness
Jacket-Pipe
Outside
Deliverylength in
1,00 m steps
Maximum
coiloutside-
Minimum
bending
radius
Weight
without
water
da
in mm
s
in mm
Da
in mm
L
in m
dR
in mm
r
in m
G
in kg/m
25,0
32,0
40,0
50,0
63,0
75,0
90,0
110,0
2,3
2,9
3,7
4,6
5,8
6,8
8,2
10,0
75 / 90
75 / 90
90 / 110
110 / 125
125 / 140
140
160
180
24 - 360 / 250
24 - 360 / 250
24 - 250 / 200
24 - 200 / 150
24 - 150 / 140
24 - 140
24 - 120
24 - 70
2530
2530
2530
2530 / 2550
2550 / 2690
2690
2700
2700
0,7 / 0,8
0,8 / 0,8
0,8 / 0,9
0,9 / 1,0
1,0 / 1,1
1,1
1,2
1,4
0,82 / 1,03
0,90 / 1,10
1,22 / 1,62
1,79 / 2,06
2,35 / 2,82
3,14
4,07
5,43
Outside
Wall-
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F L E X R O H R
Outside
Type
H - 20 + 20
H - 25 + 25
H - 32 + 32
H - 40 + 40
H - 50 + 50
H - 63 + 63
JacketDelivery- Maximum
coilPipe
length in
Wallthickness Outside- 1 m steps outside-
Minimum
bending
radius
Weight
without
water
da
in mm
s
in mm
Da
in mm
L
in m
dR
in mm
r
in m
G
in kg/m
2 20,0
2 25,0
2 32,0
2 40,0
2 50,0
2 63,0
2,0
2,3
2,9
3,7
4,6
5,8
75
90
110
125
160
180
24 - 360
24 - 250
24 - 200
24 - 150
24 - 120
24 - 70
2530
2530
2530
2550
2700
2700
0,9
0,9
0,9
1,0
1,2
1,4
0,71
0,92
1,34
1,74
2,71
3,67
Minimum
bending
radius
Weight
without
water
Outside
Type
S - 25
S - 32
S - 40
S - 50
S - 63
JacketDelivery- Maximum
coilPipe
length in
Wallthickness Outside- 1 m steps outside-
da
in mm
s
in mm
Da
in mm
L
in m
dR
in mm
r
in m
G
in kg/m
25,0
32,0
40,0
50,0
63,0
3,5
4,4
5,5
6,9
8,7
75
75
90
110
125
24 - 360
24 - 360
24 - 250
24 - 200
24 - 150
2530
2530
2530
2530
2550
0,7
0,8
0,8
0,9
1,0
0,89
1,01
1,39
2,05
2,77
Single pipe heating - 6 bar, see page F4.0 may be used for dimensions S - 75 to S-110, providing that
operation pressure will be maximum 6 bar. Admissible operating pressure [pB] see page F 4.2.
Type
S - 25 + 20
S - 32 + 20
S - 40 + 25
S - 50 + 32
S - 63 + 32
Outside
JacketDelivery- Maximum
coilPipe
length in
Wallthickness Outside- 1 m steps outside-
Minimum
bending
radius
Weight
without
water
da
in mm
s
in mm
Da
in mm
L
in m
dR
in mm
r
in m
G
in kg/m
25,0 / 20,0
32,0 / 20,0
40,0 / 25,0
50,0 / 32,0
63,0 / 32,0
3,5 / 2,8
4,4 / 2,8
5,5 / 3,5
6,9 / 4,4
8,7 / 4,4
90
110
125
140
160
24 - 250
24 - 200
24 - 150
24 - 140
24 - 120
2530
2530
2550
2690
2700
0,9
0,9
1,0
1,1
1,2
0,98
1,37
1,78
2,53
3,23
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F 4.1
F L E X R O H R
H - 25
H - 32
H - 40
H - 50
H - 63
H - 75
H - 90
H - 110
Type
H - 25 v
H - 32 v
H - 40 v
H - 50 v
H - 63 v
Watercontent
VolumeFlow
Dimensioning
FlowTransmitted Capacity
Speed
P in kW
v
in l/m
V
in m/h
w
in m/s
0,327
0,539
0,835
1,307
2,075
2,961
4,254
6,362
0,941
1,941
3,305
5,177
8,964
13,857
22,974
36,644
0,80
1,00
1,10
1,10
1,20
1,30
1,50
1,60
at spread
20 K
22
45
77
120
209
322
534
852
30 K
33
68
115
181
313
483
802
1.279
40 K
44
90
154
241
417
645
1.069
1.705
Watercontent
VolumeFlow
Dimensioning
FlowTransmitted Capacity
Speed
P in kW
v
in l/m
V
in m/h
w
in m/s
0,327
0,539
0,835
1,307
2,075
1,177
2,329
3,906
6,119
10,458
1,00
1,20
1,30
1,30
1,40
at spread
20 K
27
54
91
142
243
30 K
41
81
136
213
365
40 K
55
108
182
285
487
Heat Loss
Coefficient
kER
in
W/(mK)
0,1294
0,1642
0,1708
0,1757
0,1992
0,2186
0,2347
0,2701
60 K
7,762
9,850
10,249
10,542
11,954
13,117
14,080
16,204
50 K
6,468
8,208
8,540
8,785
9,962
10,931
11,733
13,504
Heat Loss
Coefficient
kER
in
W/(mK)
0,1115
0,1364
0,1394
0,1526
0,1745
60 K
6,688
8,183
8,366
9,158
10,468
50 K
5,573
6,819
6,971
7,631
8,723
H - 20 + 20
H - 25 + 25
H - 32 + 32
H - 40 + 40
H - 50 + 50
H - 63 + 63
Watercontent
VolumeFlow
Dimensioning
FlowTransmitted Capacity
Speed
P in kW
v
in l/m
V
in m/h
w
in m/s
0,201
0,327
0,539
0,835
1,307
2,075
0,507
1,059
2,135
3,606
5,648
9,711
0,70
0,90
1,10
1,20
1,20
1,30
at spread
20 K
12
25
50
84
131
226
30 K
18
37
74
126
197
339
40 K
24
49
99
168
263
452
Heat Loss
Coefficient
kDR
in
W/(mK)
0,2189
0,2233
0,2438
0,2740
0,2561
0,3049
60 K
13,139
13,399
14,631
16,442
15,369
18,298
50 K
10,952
11,168
12,195
13,705
12,810
15,252
1 year
5 years
10 years
25 years
50 years
10
17,9
17,5
17,4
17,2
17,1
20
15,8
15,5
15,4
15,2
15,1
80
8,0
7,8
7,7
7,6
---
90
7,2
7,0
6,9
-----
The mentioned data are corresponding to DIN 16893 for flow medium water with a safety factor of SD =
1,25.
F 4.2
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F L E X R O H R
Dimensioning
Water- Volume- Flow- Volume- Flow- Volume- Flowcontent
Flow
Speed
Flow
Speed
Flow
Speed
S - 25
S - 32
S - 40
S - 50
S - 63
Heat Loss
Coefficient
kER
in
v
in l/m
V
in m/h
w
in m/s
V
in m/h
w
in m/s
V
in m/h
w
in m/s
W/(mK)
0,254
0,423
0,661
1,029
1,633
1,099
1,826
2,853
4,446
7,055
1,2
1,2
1,2
1,2
1,2
1,191
1,978
3,091
4,817
7,643
1,3
1,3
1,3
1,3
1,3
1,283
2,131
3,329
5,187
8,231
1,4
1,4
1,4
1,4
1,4
0,1285
0,1628
0,1694
0,1742
0,1973
60 K
7,710
9,769
10,164
10,450
11,837
50 K
6,425
8,141
8,470
8,708
9,864
40 K
5,140
6,513
6,776
6,967
7,891
Dimensioning
Water- Volume- Flow- Volume- Flow- Volume- Flowcontent
Flow
Speed
Flow
Speed
Flow
Speed
S-25+20
S-32+20
S-40+25
S-50+32
S-63+32
Heat Loss
Coefficient
kDR
in
v
in l/m
V
in m/h
w
in m/s
V
in m/h
w
in m/s
V
in m/h
w
in m/s
W/(mK)
0,254
0,423
0,661
1,029
1,633
1,374
2,283
3,567
5,558
8,819
1,5
1,5
1,5
1,5
1,5
1,466
2,435
3,805
5,928
9,407
1,6
1,6
1,6
1,6
1,6
1,557
2,587
4,042
6,299
9,995
1,7
1,7
1,7
1,7
1,7
0,2003
0,1962
0,2127
0,2431
0,2473
60 K
12,040
11,811
12,810
14,640
14,921
50 K
10,059
9,891
10,730
12,264
12,529
40 K
8,078
7,971
8,650
9,887
10,137
The mentioned data are based on a medium specific thermal capacity [cm] of the water of 4187 J/(kgK),
a soil covering height [H] of 0,60 m, a thermal conductivity of the soil [E] of 1,2 W/(mK), a medium soil
temperature[TE] of 10 C and for single pipes on a medium pipe distance of 100 mm. The flow speed [w]
has to be determined specifically.
(59) TM = (TVL + TRL) : 2 TE ; Example: (80 + 60) : 2 10 = 60 K average temperature.
1 year
5 years
10 years
25 years
50 years
10
28,3
27,8
27,6
27,3
27,1
20
25,1
24,6
24,4
24,2
24,0
80
12,7
12,4
12,3
12,1
---
90
11,4
11,1
11,0
-----
The mentioned data are corresponding to DIN 16893 for flow medium water with a safety factor of SD =
1,25.
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F 4.3
F L E X R O H R
COMPONENTS
Survey
Connecting-Coupling
Elbow-Coupling
Reducing-Coupling
Fitting-Coupling
Screw-Angle
T-Piece
F 4.4
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F L E X R O H R
COMPONENTS
Connecting-c and Elbow-Couplingd
Dimension
PE-XaPipe
20 x 20
25 x 25
32 x 32
40 x 40
50 x 50
63 x 63
75 x 75
90 x 90
110 x 110
Heating - 6 bar
Press
Screwed
Sanitary - 10 bar
Press
Screwed
Con.c
Elb.d
Con.c
Elb.d
Con.c
Elb.d
Con.c
Elb.d
PVK
---
PBK
---
SVK
---
SBK
---
PVK
PBK
SVK
SBK
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
-------
-------
-------
-------
-------
Example of order:
Press-Connection-Coupling (PVK):
Screwed-Connection-Coupling (SVK):
Press-Elbow-Coupling (PBK):
Screwed-Elbow-Coupling (SBK):
According to type and dimension press connection couplings, determined from isoplus, may
consist of St 37.0 S, material No. 1.0254, acc. to DIN 2448 or brass CZ 132 or red cast iron RG
7. Screwed couplings are generally acc. to DIN 8076 in heavy brass quality.
Assembling steps of connecting-coupling see page F 4.4.7 and F 4.4.8
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F 4.4.1
F L E X R O H R
COMPONENTS
Reducing-Coupling
Dimension
PE-XaPipe
25 x 20
32 x 20
32 x 25
40 x 25
40 x 32
50 x 32
50 x 40
63 x 40
63 x 50
75 x 50
75 x 63
90 x 63
90 x 75
110 x 75
110 x 90
Heating - 6 bar
Press
Screwed
Sanitary - 10 bar
Press
Screwed
Reduction
Reduction
Reduction
Reduction
PRK
-----
SRK
-----
PRK
SRK
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
-------------
-------------
For buried sections as well as for heating installations (6 bar) generally press fittings should be
used. Inside of buildings in manholes as well as for sanitary applications (10 bar) also screwed
connections can be used.
Example of order:
Press-Reducing-Coupling (PRK):
Screwed-Reducing-Coupling (SRK):
According to type and dimension press connection couplings, determined from isoplus, may
consist of St 37.0 S, material No. 1.0254, acc. to DIN 2448 or brass CZ 132 or red cast iron RG
7. Screwed couplings are generally acc. to DIN 8076 in heavy brass quality.
F 4.4.2
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F L E X R O H R
COMPONENTS
Fitting-Coupling inside of building
with Welding-Endc or Outside-Threadd
Dimension
PE-XaPipe
Heating - 6 bar
Press
Screwed
WEc
OTd
WEc
OTd
Sanitary - 10 bar
Press
Screwed
WEc
OTd
WEc
OTd
20 x
25 x
32 x 1
40 x 1
50 x 1
63 x 2
75 x 2
90 x 3
110 x 4
---
---
---
---
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
-------------------
9
9
9
9
9
9
-------
-------------------
9
9
9
9
9
9
-------
According to type and dimension press connection couplings, determined from isoplus, may
consist of St 37.0 S, material No. 1.0254, acc. to DIN 2448 or brass CZ 132 or red cast iron RG
7. Screwed couplings are generally acc. to DIN 8076 in heavy brass quality.
Assembling steps of fitting-coupling see page F 4.4.7 and F 4.4.8
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F 4.4.3
F L E X R O H R
COMPONENTS
Heating - 6 bar
Screw-Angle
with Outside-Thread
SWAG
20 x
25 x
32 x 1
40 x 1
50 x 1
63 x 2
75 x 2
90 x 3
110 x 4
---
9
9
9
9
9
9
9
9
Sanitary - 10 bar
Screw-Angle
with Outside-Thread
SWAG
9
9
9
9
9
9
-------
Example of order:
Screw-Angle with Outside-Thread (SWAG):
Heating: SWAG - 90 x 3, 6 bar, with screwed fitting
for isopex-Heating Type H-90
F 4.4.4
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F L E X R O H R
COMPONENTS
T-Piece Heating, 6 bar
Press-T-Piece (PT)
Branch resp. soil pipe da2
Passage
da1
da3
25
25
32
32
40
40
40
50
50
50
50
63
63
63
63
75
75
75
75
90
90
90
90
110
110
110
25
25
32
25
32
40
25
32
40
50
32
40
50
63
40
50
63
75
50
63
75
90
75
90
110
9
9
9
9
9
9
9
32
9
9
9
9
9
9
9
9
9
9
9
-----
-----
9
9
40
50
63
90
110
Zeichnung PT
aus Preisliste
9
9
9
---
75
Screw-T-Piece (ST)
Branch resp. soil pipe da2
9
9
9
9
9
---
---
---
9
9
9
---
9
9
9
9
9
-----
-----
-----
-----
---
---
9
9
9
9
9
9
9
9
9
9
9
---
---------------
-----
-----
-----
---
---
---
9
9
9
9
---
-------
-----
9
9
9
9
9
9
---
-----
-----
9
9
-----
---
9
9
9
---
9
9
25
32
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
40
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
50
63
75
90
110
Zeichnung ST
aus Preisliste
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
In case of order the three dimensions of the tee Piece [da1-3], operating pressure and kind of
connection to isopex-pipe ends should be mentioned. Press fittings or screwed connections
with screwed-caps can be used.
For buried sections as well as for heating installations (6 bar) generally press fittings should be
used. Inside of buildings in manholes as well as for sanitary applications (10 bar) also screwed
connections can be used. Other dimensions on request.
Will be continued next page F 4.4.6
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F 4.4.5
F L E X R O H R
COMPONENTS
Passage
da1
da3
20
20
25
25
32
32
32
40
40
40
40
50
50
50
50
63
63
63
63
20
20
25
20
25
32
20
25
32
40
25
32
40
50
32
40
50
63
9
9
9
9
9
9
-------------------------
25
9
9
9
9
9
-------
9
-----------------
32
40
50
Screw-T-Piece (ST)
Branch resp. soil pipe da2
63
9
9
9
-----
9
9
-----
9
9
-----
9
9
-------
9
---------------
-------------
-------
20
25
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
32
40
50
63
Zeichnung ST
aus Preisliste
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
In case of order the three dimensions of the tee Piece [da1-3], operating pressure and kind of
connection to isopex-pipe ends should be mentioned. Press fittings or screwed connections
with screwed-caps can be used.
For buried sections as well as for heating installations (6 bar) generally press fittings should be
used. Inside of buildings in manholes as well as for sanitary applications (10 bar) also screwed
connections can be used. Other dimensions on request.
Example of order, passage x branch x passage (da1 x da2 x da3):
Press-T-Piece (PT):
Screw-T-Piece (ST):
According to type and dimension press tee pieces, determined from isoplus, may consist of St
37.0 S, material No. 1.0254, acc. to DIN 2448 or brass CZ 132 or red cast iron RG 7. Screwed
tee pieces are generally acc. to DIN 8076 in heavy brass quality.
Assembling steps analogue respectively corresponding like connecting-, fitting- and elbowcoupling see page F 4.4.7 and F 4.4.8
F 4.4.6
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F L E X R O H R
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F 4.4.7
F L E X R O H R
F 4.4.8
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
House-entry-elbows are useful for connecting buildings without cellars by passing the concrete
ground-plate of the house. They will be produced generally in standard lengths of 1,00 x 1,50 m.
Depending from kind of flexible pipe with steel, copper or PE-Xa medium pipe. For post
insulation of the connection spot in the soil a jacket pipe connecting coupler will be required,
see Design-Manual, chapter V.
In case of isopex-pipes the connection with the continuing pipe will be made inside of the
building by using connection couplers with welding ends or outside threads, see page F 4.4.3.
Orders of house-entry-elbows should clearly indicate all medium- and jacket pipe dimensions
respectively type and operating pressure. In case of double pipes additionally the position of
the bend, vertical (s), horizontal (w) or falling (f) should be mentioned. In case of different
medium pipe diameters, the position of the smaller medium pipe diameter will be generally in
12:00 oclock position.
Example of order:
House-Entry-Elbow (HEB) isoflex:
Single:
Double-II: HEB-s - 2 x 28 / 90
HEB - 28 / 75
for isoflex - Standard
House-Entry-Elbow isopex-Heating:
House-Entry-Elbow isopex-Sanitary:
Single:
Single:
Double:
Double:
Medium- and jacket-pipe dimensions isoflex see page F 2.0, isocu see page F 3.0 and isopex
page F 4.0. All connection couplings, protection- and end caps as well as jacket-pipe couplers
are not included within the delivery of the elbow.
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F 5.0
Front View
Bifurcated pipes are used for transition of two single pipes to one double pipe and are produced generally
with the same dimensions. For applications of isoflex and isopex-heating, bifurcated pipes will consist of
a black medium pipe St 37 S acc. to DIN 2448/1629. For applications of isopex-sanitary acc. to DIN 2440
zinc acc. to DIN 2444 and with pipe-threads acc. to DIN 2999 for thread-couplers acc. to DIN 2986. In
case of isocu with copper pipes acc. to DIN 1754/17671.
For post insulation of the connection spots in the soil, corresponding connection couplers will be required,
according to the jacket-pipe dimensions, see Design-Manual, chapter V. Connection with isopex-pipes
will be made by use of connection couplers with welding end or outside thread, see page F 4.4.3.
Orders of bifurcated pipes should clearly indicate all medium- and jacket-pipe dimensions respectively
kind and operating pressure. In case of double pipes the position of the smaller dimension will be
generally in 12:00- oclock position.
Example of order:
Bifurcated Pipe (HR-I) isoflex:
HR-I for isoflex, 2 x Single 28 / 75
to 1 x Double 28 + 28 / 90
Medium- and jacket-pipe dimensions isoflex see page F 2.0, isocu see page F 3.0 and isopex page F
4.0. All connection couplings as well as jacket-pipe couplers are not included within the delivery of a
bifurcated pipe. Due to manufacturing reasons the jacket-pipe dimensions may differ partly from the
PELD-dimensions of the flexible pipes. Available dimensions and measures on request.
During assembling the correct position of single- and double pipes, respectively the position of the
bifurcated pipe as well as the axial measures A and H has to be considered. The condition for expansion
compensation (L-, Z, or U-elbow) has to be provided at the transitions of the single-pipe system before
the bifurcated pipe, because bifurcated pipes have to be installed generally at pipe-static neutral pipeline
spots. In case of changing of the system within an exit-pipe of a branch, between branch and bifurcated
pipe a rigid fitting part of at least 2,50 m lengths has to be installed for compensation of lateral expansion,
see also page F 9.2.
F 5.1
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
ACCESSORIES
Press Tool
For the pressing procedure three types of tools are
available:
>> Mechanical press tool
for isopex-pipes up to dimension of 40 mm
>> Hydraulically press tool
for isopex-pipes up to dimension of 40 mm
>> Hydraulically press tool
for isopex-pipes starting from 50 mm
All tools incl. all required accessories like presspincers, -blocks and -ridges, expansion pincer and
-heads as well as the corresponding small
accessories are completed in a stable metal
suitcase.
Depending from requirements they can be used for
some days or weeks against payment. During this
time the user of the tools will be exclusively
responsible for correct function, cleaning and
complete return of the equipment.
Bending Tool
For the procedure of bending of isoflex or/and
isocu the hydraulically isoplus-bending tool incl.
pump and pressure hoses will be available.
Bending will be made in three to four steps.
Depending from kind of flexible pipe different
minimum bending radius should be considered.
See page F 2.0 and F 3.0.
The use of a not suitable bending equipment is not
allowed. In order to avoid damages of the flexible
pipes bending around edges like foreign pipe-lines,
squared timber, buildings- or wall-corners are not
permitted.
Depending from requirement the equipment may be used for days or weeks. During this period
the user will be exclusively responsible for correct function, cleaning and the complete return of
all parts.
For bending of isopex-pipes the use of a tool will be not possible, due to the high self-elasticity
of the medium pipe.
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F 6.0
ACCESSORIES
Protection Cap
In order to protect the PUR foam against moisture
by means of condense, inside of buildings (dryingrooms) protection caps should be used. These are
consisting of age-resistant neoprene-rubber and will
be used as simplex- or doublex-cap, depending
from kind of flexible pipe-type.
The pipe laying company will be responsible to put
on the protection cap before connecting with the
building line. These caps have to be protected from
fire, may not be cutted and may not be used for
post installation. The installation of the pipe ends
without protection cap (AK) is not permitted.
Available PE-jacket-pipe dimensions see page F
2.0, F 3.0, F 4.0 and F 4.1.
End Cap
Within moisten-rooms heat shrinkable end caps
should be used in order to protect the PUR-foam
against moisture. These consist of molecular cross
linked modified and not meltable Polyolefin.
Additionally the end caps will protect against
diffusion of PUR-foam cell gases which will occur at
open pipe ends.
The pipe laying company will be responsible to put
the end caps on before the connection with the
building line will be made. The end caps should be
protected against fire, may not be cutted and may
not be used for post-installation. To install the pipe
ends without end cap (EK) is not permitted.
Available types and assembling instructions see
Design-Manual,
chapter
accessories
and
assembling guidelines, page Z 5.0 and M 7.0.
F 6.1
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
ACCESSORIES
Wall Duct
Wall sealing rings will avoid water penetration at
wall entries in manholes or buildings. The pipe
laying company will be responsible to put in the wall
sealing ring and to centralise it at the wall entry
before the connection to the building line will be
made. The installation of flexible pipes without wall
sealing rings (DR) is not permitted.
If pressure-water-tight systems will be used, a
suitable security measure has to be provided in
order to avoid a damage of the PELD-jacket-pipe.
Available types and assembling instructions see
Design-Manual,
chapter
accessories
and
assembling guidelines, page Z 6.0 and M 8.0.
Distributing Manhole
A distributing manhole will be used for checking of
installations like branches within a isopex-pipeline.
This inspection manhole incl. cover-plate consists
of polyethylene (PE) and will be delivered in
dimension of 800 mm and an installation height
respectively depth of approx. 700 mm.
The universal and water-tight construction allows
the connection of up to eight pipes with jacket-pipe
dimensions of 65 to 180 mm.
Before the flexible pipe will be installed, the pipe
layer should install the corresponding sealing set.
This consists of a closed heat shrinkable sleeve as
well as of a centre ring in accordance with the
jacket-pipe dimension. The sealing sets are not part
of the delivery of the distributing manhole.
At a pipe covering height of 0,4 m the maximum
admissible load of the cover will be 50 kN/m. In
case that higher coverings will be reached, a well
ring respectively a soak-hole concrete ring should
be installed above the PE-manhole.
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F 6.2
ACCESSORIES
Twin-Accoutrement
This fitting unit, consisting of two ball valves, may
be used for all isoplus-flexible pipes for heating
installations. It should be installed at the wall in
closed position with the included mounting-plate.
The distance between the ball valves with reduced
passage is 140 mm, and the distance of the drilling
holes is 145 mm, the distance of the ball-valve axis
to the wall is 100 mm.
Casing and welding ends are made of St 37.0, ball
and gear-shaft of chromium-nickel-steel, ring and
sealing of PTFE, available for medium pipe
dimensions of to maximum 2.
For isopex type H-25 to H-63 additionally two
connection couplings with welding ends are
required, see page F 4.4.3.
One-Time-Ball-Valve
One-time-ball-valves respectively connection-ballvalves are suitable for all isoplus-flexible pipes for
heating applications. They will be used to close a
building section, which will be continued later on.
As end piece in closed position, the existing pipe
line may be continued at any time, without draining
or stopping the pipe line operation.
Post-insulation will be made by use of an end
coupler. Available types see Design-Manuel,
chapter accessories, page Z 4.0. In case of using
with isopex type H-25 to H-110 additionally a
connection coupling with welding end will be
required, see page F 4.4.3.
Others
Other accessories like expansion pads, PUR-foam, pipe supports and pipe warning tape are
also mentioned in Design-Manual, chapter accessories, page Z 7.0 to Z 9.0.
F 6.3
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
Passage in mm
Da1
Da3
65
75
75
90
90
90
110
110
110
110
125
125
125
125
140
140
140
140
160
160
160
160
180
180
180
180
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
65
65
75
65
75
90
65
75
90
110
75
90
110
125
90
110
125
140
110
125
140
160
125
140
160
180
-----------------
75
90
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
---------
110
125
140
160
180
Zeichnung
aus Preisliste
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
GFK-Assembling-Elbow 90
Da in mm
Elbow
Da in mm
65
75
90
110
---
125
140
160
180
9
9
9
Elbow
9
9
9
9
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F 7.0
isocu:
GFK-T - 75 x 65 x 75
for isocu, Type II to I to II
isoflex:
GFK-B - 90
for isoflex, Type 1 x reinforced
GFK-Assembling-Elbow:
isopex:
GFK-B - 180
for isopex, Type H-63+63
Assembling Half-Shells
at the example isopex-T-Piece
isopex-pipes will be connected right-angled with Tpieces acc. to page F 4.4.5 respectively F 4.4.6.
The dismantled pipes lengths of the three pipe ends
have to be limited to maximum 150 mm each. In
case that one of the jacket-pipes should be
reduced, the reducing ring has to be prepared.
Before assembling the PE-reducing ring should be
marked and cut off by two wedge cuts. The sealing
tape should be put into the grooves of the both
inside rings and has to be pressed to the cut- and
surface.
All jacket-pipe ends should be cleaned with a PEcleaner before the sealing tape will be put in.
F 7.1
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
Passage
Da1 in mm
65
75
65
75
90
110
125
140
160
180
1
2
2
5
5
6
6
---
2
2
5
5
6
6
---
90
2
5
5
6
6
8
110
125
140
160
180
Zeichnung
aus Preisliste
15
15
6
8
9
15
8
8
9
8
8
9
8
26
26
Elbow
--1
1
5
5
6
6
8
For branches the diameter of passage Da3 is not relevant for determination.
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F 7.1.1
F 7.2
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
ASSEMBLING
On page F 8.0 to F 8.2.3 described assembling recommendations should be only a survey
concerning the most required working steps and- conditions. Also the valid and detailed
instructions and information mentioned in the Design Manual chapter M Assembling
Instructions have to be considered.
Delivery
isoplus-flexible pipes will be delivered in coils
(Diameter 2,00 m) per truck to the building site
respectively to the material stock. In order to protect
the medium pipe the pipe ends are closed with
yellow caps, which should be removed not before
the connection of the pipes.
In case of a further transportation of the pipes the
loading area of the truck should be checked
concerning rigid stick out parts. The pipes should
lay plain and symmetrically on the loading area.
Unloading
Unloading will be made properly and carefully by
the pipe-layer or third parties. In case of unloading
by use of a crane, belt with a width of at least 10 cm
should be used. Fork-ends of fork-lifts have to be
covered with protecting pipes.
Pulling and rolling of flexible pipes on the ground as
well as the use of steel ropes or chains is not
allowed because of scratches and pressure-spots
at the jacket-pipe, caused by uneven grounds.
Storage
Flexible pipes have to be stored on even and dry
surfaces, free of stones. Ground water endangered
and water stowed soils should be avoid. Sand
banks respectively -sacks or squared timber in starconstellation may be used as support.
In case that the pipes will be stored for a longer
time, suitable protection measures against all
weather conditions have to be provided. During a
period of frost the jacket-pipe as well as the
isoplus medium pipe has to be protected against
strikes and shocks.
Copy only after agreement with isoplus Fernwrmetechnik GmbH; Technical modifications reserved; Edition 04/2005
F 8.0
ASSEMBLING
Accessories for flexible pipes have to be stored
within a lockable room or container. The pipe-layer
respectively a third party will be exclusively
responsible for the correct storage of all system
components. He will confirm the receipt of the
complete material and will control the distribution of
the material during the construction period.
Cut Off
Flexible pipe-coils have to be opened from inside,
due to the remaining tension.
Attention: Danger of injuring !
For assembling the isoplus-flexible pipes will be
uncoiled and cutted to the corresponding lengths.
The coils should be also turned accordingly.
Additionally it should be considered, that the coil
will be not pulled on an uneven respectively stone
containing ground.
After the right-angled cutting of the flexible pipe, the
jacket-pipe and the PUR-foam should be cutted in a
distance of max. 150 mm from the cut. Then the
jacket will be peeled by use of a suitable tool and
the foam, as well as the remaining foam will be
removed.
Attention: The red E/VAL-diffusion barrier of the
isopex-pipe, 6 bar - heating, may be not destroyed !
Processing
Pipe laying and processing of isoplus-flexible pipes
will be generally possible up to an outside
temperature of + 10 C. At temperatures below
10C eventually suitable precautions should be
provided, depending from dimensions. Up to PELD
jacket-pipe dimension of 90 mm the assembling of
flexible pipes will be also possible at 0 C.
In case of lower temperatures PUR-foam and jacket
pipes can break. The risk will generally exist in case
of jacket pipes > 90 mm and in case of isopexdouble pipes at temperatures below 10 C.
F 8.1
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ASSEMBLING
In case that isoplus-flexible pipes should
nevertheless laid at such low outside temperatures
the suitable processing temperature has to be
reached by storing the pipes inside of a heated
room or by filling them with warm water and/or by
heat supply (max. 40 C on to the PELD-jacket) by
use of a suitable equipment. Water filled pipes may
not be stored during a longer period of frost.
In case that the pre-heating will be carried out by
use of a gas-burner, a burner-head of minimum
50 mm has to be used. Preheating should be made
with yellow flame in pendulum movements over a
longer distance. Selective heating of the jacket-pipe
will lead to damages of the flexible pipe system.
Pipe-Laying
Assembling of flexible pipes will be normally on a 10 cm sand bed. Eventually required
manholes should be provided as working area. Due to the long delivery lengths this requirement
will occur only exceptionally. Supports have to be provided in a distance of 2,00 m.
Flexible pipes may be laid side by side or on top of each other into the trenches. Pipe-laying by
use of a special horizontal flush-drilling procedure will be also possible. The instruction of the
executing company has to be strictly considered.
Underground Work
Soil-works have to be carried out in accordance with the general valid guidelines and standard
for civil engineering. Also the additional and different local government regulations have to be
considered. Detailed information concerning civil engineering is mentioned in chapter
assembling instructions page M 2.0 up to M 2.5.
Assembling progress will depend essentially from a trench construction according to DIN, as
well as from the quality of all executing works and therefore from the expected life time of a
flexible pipeline !
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F 8.2
ASSEMBLING
Trench Depth
The depth of soil [T] in the pipe-trench will be calculated from covering height [H], PELDjacket-pipe diameter [Da] and height of the pipe support respectively sand-bed. Minimum
covering height of isoplus-flexible pipes is 0,40 m. Frost-depth in middle Europe is 0,80 m.
Jacket-pipe-
Da
in mm
Covering height
H
in m
Soil-depth
T
in m
65
75
90
110
125
140
160
180
0,40
0,40
0,40
0,40
0,40
0,40
0,40
0,40
0,57
0,58
0,59
0,61
0,63
0,64
0,66
0,68
The values mentioned in the table are valid for the given covering heights and a sand-bed
respectively assembling support of 0,10 m. In case of other covering heights the difference
value from the mentioned covering height has to be added or reduced to the depth [T].
Trench Width
The soil-width [B] will be calculated in trench-sections without any foreign elements from PELDjacket-pipe diameter [Da] and the minimum assembling distance [M]. In case that expansion
pads will be required for isoflex or isocu at alterations of direction or at branches, the distance
[M] has to be enlarged about 80 mm.
Jacket-pipe-
Da
in mm
Minimum
M
in mm
Soil-width
B
in m
F 8.2.1
65
75
90
110
125
140
160
180
100
100
100
100
100
100
100
100
0,43
0,45
0,48
0,52
0,55
0,58
0,62
0,66
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ASSEMBLING
The width [B] mentioned in table, page F 8.2.1, will be valid for two pipes of the same PELDjacket-pipe diameter. For the pipe laying of double pipes this value will be calculated as follows:
BDoublepipe = Da + 2 M
[m]
(97)
For all other applications, i.e. in case of several pipes [x] the soil-width [B] will be calculated as
follows:
B = x Da + (x+1) M
[m]
(80)
Sand-Bed
After assembling of flexible pipes and eventually required sealing and insulation works, all kind
of tests which are part of the performance have to be carried out. The following details have to
be considered:
The statically calculated covering height has to be kept
Expansion pads have been assembled in the given lengths and
sizes and are secured against soil-pressure
All couplers have been foamed and recorded, the breakthrough to the
buildings and constructions have to be closed
In case of thermal pre-stressing the given expansions and the corresponding
expansions should have been reached and recorded
The pipeline guidance has to be in correspondence with the valid trench-design
Before the sand-bed will be refilled again, the trench has to be approved from the responsible
site-supervisor.
Thereafter the isoplus-flexible pipes have to be refilled carefully with sand with a grain structure
of 0 - 4 mm (class NS 0/2) in layers up to at least 10 cm. Then the sand should be compressed
manually. Especially attention should be given to gaps or gores in order to avoid hollow spaces.
Such areas have to be compressed separately, in order to avoid settings or movings later on.
During these works pipe supports should be removed.
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F 8.2.2
ASSEMBLING
Exact structure of sand and particle-size is mentioned in Design Manual, chapter assembling
instructions, page M 2.3.1.
Re-Filling
After completion of the sand-bed the trench will be re-filled by using the digging material.
Compressing of several layers will be necessary. The filling and compressing of the trench has
to be carried out simultaneously on both sides of the pipes, in order to avoid movements or
lifting of the pipeline.
After filling of a 20 cm layer, compressing machines like a compressor or explosioncompressing-ram may be used (weight up to 100 kg). The permissible surface load is 40 N/cm
resp. 4 kg/cm for cold pipelines.
The additional technical contract conditions and guidelines for digging and soil-works for road
construction, ZTV A and ZTV E, have to be considered additionally. The required compressing
data [DPr], are mentioned in Design Manual, chapter assembling instructions, page M 2.4.
F 8.2.3
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PROJECT WORK
General
For flexible pipe systems as well as for rigid KMR-compound systems a high degree of
conversion of special know-how will be required. The following examples will show proved pipe
laying technology of isoplus-flexible pipes.
Covering
height [H]
Flex pipe
Type
Dimensions
Spread in K
isoflex
isocu
Single
Double I
Single
Double I
Double II
28/75 28/90
2 28/90
22/65 28/75
2 22/90
2 28/90
---
---
20
30
40
---
---
20
30
40
20
30
40
0,40 m
0,60 m
84
58
69
48
90
63
80
57
71
50
29
20
38
26
27
19
23
16
20
14
40
28
35
24
30
21
0,80 m
44
36
49
44
39
15
20
14
13
11
21
19
16
1,00 m
36
29
40
36
32
12
16
12
10
17
15
13
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F 9.0
PROJECT WORK
U-Compensation
In case of pipe laying lengths longer than Lmax Ucompensation may be used. From U-elbow to Uelbow the corresponding maximum pipe laying
length Lmax has to be kept. The length [a] and the
width [b] of the U-elbows should be at least the
double of the minimum bending radius [r].
Wave-Technology
Pipe laying in wavy lines may be also used in case
that Lmax will be exceeded. The flexible pipes will be
laid in wavy lines with a cross-measure [q] of at
least 2,00 m.
At the beginning and at the end of such a section a
90 angle with a corresponding minimum bending
radius [r] has to be provided. Branches can be not
installed in this kind of technology.
Branch-Technology
The connection of isoflex- resp. isocu-pipes will be
made by use of pre-fabricated 45- or parallelbranches.
It will be generally possible, to produce all kinds of
branches, as described in Design Manual, page B
3.0, chapter Components.
The connecting branch-pipe to the main pipe will be
made by use of isoflex or isocu, depending from
requirement, that means no additional medium pipe
and jacket-pipe reduction will be necessary.
45 T-Branch
F 9.1
Parallel-Branch
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PROJECT WORK
Application isopex
Transition KMR
Before connection of isopex on a axial or/and lateral expanding pipe system like isoplusjacket-pipe (KMR), the expansion has to be compensated. That means, that before the
transition of the KMR pipe an L-, Z- or U-elbow has to be projected, or an anchor (FP) has to be
provided.
L-Elbow
Z-Elbow
U-Elbow
45 T-Branch
Parallel-Branch
Expansion side legs of KMR-systems have to be provided with expansion pads (DP), according
to the isoplus line-drawing.
Branch isopex
Alternatively it will be possible to carry out branches from several pipe systems with different
kinds of connections and branches. The following isopex-branch technologies (possibilities AD), page F 9.2.1 and F 9.2.2 show the practically most used possibilities. In case of transitions
to expanding pipe systems like i.e. isoplus-KMR (A-C), the pipe static has to be considered,
see above. In case of other applications please contact isoplus-application engineers.
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F 9.2
PROJECT WORK
isoplus-KMR isopex
Possibility A
According to the Design Manual, chapter
components, page B 3.0, an isopex-connection
coupling with welding end at one side made of St
37.0, will be welded to the corresponding branchsteel pipe of the prefabricated insulated branch
(TA). Connection coupling see page F 4.4.3,
assembling see page F 4.4.7.
The post-insulation at this spot will be made by use
of a connection coupler or reducing coupler,
according to Design Manual, chapter V
Connection Technology Jacket-Pipe. Reducing
couplers are only necessary if the outside diameter,
[Da] of the jacket pipe will be not the same as
outside diameter of the isopex-pipe.
isoplus-KMR isopex
Possibility B
In case that house connections have to be installed
later on into a pipeline which is still not in operation,
the installation will be also made by use of a
isopex-connection coupling with welding end at one
side made of St 37.0
The insulation of the main pipe will be removed for
a length of maximum 400 mm. The branch diameter
of the medium pipe will be tapped or burned out.
Thereafter the connection coupling will be welded
electrically or autogenously to the rigid isoplusKMR-system, preferable in 45 angle. Connection
coupling see page F 4.4.3, assembling see page F
4.4.7.
Post-insulation at this spot will be carried out by use
of a PEHD-assembling branch, see Design Manual,
chapter V Connection Technology Jacket-Pipe.
F 9.2.1
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PROJECT WORK
isoplus-KMR isopex
Possibility C
In case that the rigid PEHD-jacket-pipeline will be
already in operation, the connection has to be
carried out by tapping procedure and by use of
isopex-connection coupler with one-side welding
end made of St 37.0.
The insulation of the main pipe will be removed for
a length of maximum 400 mm. Thereafter the
corresponding dimensioned tapping lock will be
welded electrically to the rigid isoplus-KMRsystem, preferable with an angle of 45. Available
tapping locks see Design Manual, chapter
accessories, page Z 3.0.
After the tapping has been carried out in
accordance to Design Manual, page M 6.0, also the
connection coupling has to be welded electrically to
the tapping lock. Connection coupling see page F
4.4.3, Assembling see page F.4.4.7.
Post-insulation at this spot will be carried out by use
of PEHD-assembling branch, see Design Manual,
chapter V Connection Technology Jacket-Pipe.
Due to the bigger nominal diameter of the tapping
lock eventually an reinforced insulation thickness
will be required at the branch, respectively a
reducing coupler (RM) has to be provided.
isopex isopex
Possibility D
Branches within the isopex-system will be carried
out with isopex-T-pieces which should be
preferable assembled with a branch-angle of 45.
See page F 4.4.5 and F 4.4.6.
The flexible pipes will be cut right-angled and the
insulation will be removed at all three ends to a
length of maximum 150 mm. Thereafter the T-piece
has to be fixed at the pipe ends, as described on
page F 4.4.7 and F 4.4.8.
Post-insulation of this branches will be carried out
with GFK-assembling branches, see page F 7.0,
assembling according to page F 7.1.
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F 9.2.2
PROJECT WORK
House Connection
45 T-Branch
Buildings can be connected directly up to a
distance of 9,00 m with isoflex and isocu, by using
a 45-branch.
Before the house-entry an expansion side-leg of a
length corresponding to the double of the minimum
bending radius [r] has to be provided. This will
guarantee that inside of the building no expansion
and no other strength have to be compensated. In
case of isopex a limitation of length will be not
necessary.
Parallel-Branch
In case of parallel connections an expansion sideleg with a length according to the minimum bending
radius [r] has to be provided for the exit pipe of the
branch.
From this side-leg to the building the max.
permissible pipe laying length [Lmax], has to be
considered in case of isoflex and isocu, see page
F 9.0, for longer length one of the described pipe
laying possibilities should be used, see page F 9.1.
In front of the house-entry a side-leg, preferable
with the double length of the minimum bending
radius [r] has to be provided, for the same reasons
as at 45-connection.
A limitation of the length is not necessary in case of
isopex.
Sloping Terrain
In case that big height-differences i.e. terrainembankments have to be overcome, isoplusflexible pipes will be particularly suitable.
The connection to the main pipeline will be made as
already described with 45- or parallel-branch.
F 9.3
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PROJECT WORK
House Connection without Cellar
Elbow - Outside
According to requirement KMR-elbows with
standard side-legs or 1,00 1,00 m length will be
used, see Design Manual, chapter components,
page B 2.0.
In connection with isopex connection couplers with
one-side welding end will be required, see page F
4.4.3, assembling see page F 4.4.7.
Post-insulation of the connection spots will be made
by use of corresponding connection couplers, see
Design Manual, chapter V Connection-Technology
Jacket-Pipes.
Elbow - Inside
House-entry-elbows (HEB) with a standard delivery
length of 1,00 1,50 m will be also used for houses
without cellar, see page F 5.0.
This solution will guarantee that there will be no
connection coupler in the foundation and in the
area of the ground-plate of the house. Postinsulation of the connection spots will be made by
use of a connection coupler.
Guiding Pipe
During construction of the house a suitable and
flexible guiding pipe has to be installed into the
foundation and into the ground-plate. The diameter
of the protecting pipe should be at least 30 mm
bigger than the PELD-jacket-pipe dimension of the
flexible pipe.
Attention: Minimum bending radius [r] of the used
flexible pipe has to be kept absolutely.
Special
Example
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F 9.3.1